Continuous forms assembly

ABSTRACT

A continuous form envelope assembly, wherein a plurality of superimposed plies define mailing envelopes with inserts, including return envelopes therein. Transverse lines of weakening across the plies define the individual envelopes. The return envelope, which is an insert, is defined by two plies, one of which includes a flap formation whereby the return envelope may be closed. The other ply defining the return envelope, includes a protective portion adjacent the flap and which is secured to the outer envelope so that when the return envelope is extracted from the outer envelope, the protective portion remains with the outer envelope.

Juszak et al.

[451 Sept. 16, 1975 1 CONTINUOUS FORMS ASSEIVIBLY [75] Inventors: JosephJ. Juszak, Crystal Lake;

Howard K. Absler, Skokie, both of Ill.

[73] Assignee: Uarco Incorporated, Barrington, Ill.

[22] Filed: Mar. 11, 1974 [21] Appl. No.: 450,147

[52] U.S. Cl. 229/69; 229/73; 229/85 [5 l] Int. Cl. B65D 27/10 [58]Field of Search 229/69, 73, 85

[56] References Cited UNITED STATES PATENTS 3,104,799 9/1963 Steidinger229/69 X 3,419,286 12/1968 Noonan et al. 229/69 X PrimaryExaminer-William 1. Price Assistant ExaminerStephen P. Garbe Attorney,Agent, or Firm-Wegner, Stellman, McCord, Wiles & Wood 5 7 ABSTRACT Acontinuous form envelope assembly, wherein a plurality of superimposedplies define mailing envelopes with inserts, including return envelopestherein. Transverse lines of weakening across the plies define theindividual envelopes The return envelope, which is an insert, is definedby two plies, one of which includes a flap formation whereby the returnenvelope may be closed. The other ply defining the return envelope,includes a protective portion adjacent the flap and which is secured tothe outer envelope so that when the return envelope is extracted fromthe outer envelope, the protective portion remains with the outerenvelope.

5 Claims, 3 Drawing Figures CONTINUOUS F ASSEMBLY BACKGROUND OF THEINVENTION This invention relates to continuous business-form assemblies,and more particularly to continuous form envelope assemblies formed ofsuperimposed plies and having insert material including at least onereturn envelope therein.

Representative prior art includes Steidinger U.S. Pat. No. 3,104,799;then Van Malderghem U.S. Pat. No. 3,554,438 and MacDougall, U.S. Pat.No. 3,652,007.

Recent years have seen a substantial upsurge in the use of businessforms of the type that can be placed in the mail with information placedthereon by computeroperated printers or manually-operated tabulators.This upsurge is principally due to the invention disclosed in theabove-identified Steidinger patent wherein a totally sealed envelopehaving insert material already therein can have information inscribed onthe envelope and can be placed in the mail without the usual need forstuffing. The elimination of stuffing operations also eliminates theneed for correlating insert material with the envelope so that theproper envelope bearing the proper insert material is directed to thecorrect recipient.

Moreover, as disclosed by Steidinger, the insert material may include areturn envelope so that all or part of the insert material may bereturned to the sender of the original envelope in the enclosed returnenvelope.

Naturally, such advantages have strongly commended the use of structuresmade according to the teaching of Steidinger. A variety of structureshave evolved which include return envelopes. Frequently, the returnenvelope is made using a pressure sensitive transfer adhesive as theflap sealing adhesive. This adhesive strip is protected by a removablebacking which must be removed by the recipient prior to sealing thereturn envelope. In other instances, the ply forming the side of thereturn envelope other than that bearing the flap is provided with aremovable chip which overlies the adhesive for ease of manufacture andwhich may provide a measure of protection for the adhesive. In thiscase, rather than removing a piece of tape to expose the adhesive, thechip must be removed so as to enable the flap to be moistened and foldedover for sealing of the return envelope.

I-Ieretofore, such means have generally been desirable principally interms simplifying the manufacture of the form and, to a lesser extent,in precluding the adhesive on the flap of the return envelope fromadhering, due to moisture conditions in the mail or in storage, to theinterior of the original mailer, thereby precluding easy removability ofthe return mailer. However, the desirability of providing such meansintroduces an undesirability in terms of requiring the recipient toperform an otherwise unnecessary operation in terms of SUMMARY OF THEINVENTION It is the principal object of the invention to provide a newand improved continuous form envelope assembly having insert material inthe form of a return envelope. More specifically, it is the object ofthe invention to provide such an envelope wherein the adhesive on theflap of a return envelope within the mailer is protected until such timeas the mailer is opened and does not require the recipient to perform apositive act to remove the protection for such adhesive.

An exemplary embodiment of the invention achieves the foregoing objectin a construction including a 'plurality of superimposed plies defininga continuous business form envelope assembly. The outermost ones of theplies define the front and back of mailers while intermediate pliesdefine insert material within the 'mailers. Transverse lines ofweakening across the plies provide for separation of the assembly intoindividual envelopes for mailing purposes.

Two of the intermediate plies define return envelopes. One such plyincludes a flap having an adhesive of the moistenable type facingthe'other intermediate ply. The other intermediate ply includes a chipaligned with the adhesive bearing flap which chip is loosely attached tothe remainder of the ply, the remainder defining the other side of thereturn envelope. The chip is secured to the outer envelope such that,upon opening the mailer to extract the return envelope, the chip remainswith the outer envelope, while the return envelope is easily pulled awayfrom the chip due to the loose connection. As a result, when theoriginal mailer is opened, the adhesive is automatically exposed so asto eliminate the need for the removal of a tape or a chip by the user.

According to the preferred embodiment, the return envelope is atop-opening envelope and the chip is L- shaped with the base thereofsecured, as by a glue line, to the outer envelope.

Other objects of the invention will become apparent from the followingspecification taken in conjunction with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS DESCRIPTION OF THE PREFERRED EMBODIMENT Acontinuous business form envelope assembly is illustrated in FIG. I andis folded in a zig-zag stack, generally designated 10, as isconventional. The assembly includes a plurality of individual envelopes12 which are defined by transverse lines of weakening 14, normally inthe form of perforations, extending across the plies defining theassembly. Running longitudinally of the plies are removable controlpunch margins 16 as is well known.

Referring now to FIGS. 2 and 3, an individual envelope 12in the assemblywill be described. It is to be understood that all of the envelopes areidentical, are

.formed of elongated plies, and are separated by the lines of weakening14. A first ply is designated 18 and may serve as the so-called recordply as is well known in the art. At its opposite longitudinal edges, itis provided with the control punch margins 16 having a plurality ofpin-feed holes 20 therein.

The immediately subjacent ply 22 defines the front of the individualenvelope or mailer in the assembly. Near one side is provided aremovable stub 24 which is separable from the remainder of the ply 24along the line of weakening 25. The stub 24 forms part of a tear stripby which access to the interior of the mailer may be achieved. Finally,the ply 22 is also provided by the control punch margins 16.

The next lowermost ply 26 is optional and may be an insert. Through theuse of spot carbons or the like (not shown) on the back side of the ply22, information may be selectively transmitted and imprinted on theinsert 26. Means by which such is accomplished are well known in the artand form no part of the instant invention.

Ply 26 is die cut at margins 28, 30 and 32 so that when in the completedenvelope assembly, those three margins will be free from attachment tothe envelope. The fourth margin includes a stub 34 which is in line withthe stub 24 and which is separable from the remainder of the insert ply28 by a line of weakening 36. When assembled, the stub 34 serves as anattaching portion to maintain the insert 28 in a predetermined locationwithin the envelope so as to insure proper alignment during animprinting process. When the envelope is opened by removal of the stubas is well known, the insert 28 will be free from attachment to theinner envelope and may be easily removed.

A further ply 38 defines the front of a return envelope contained withinthe outer envelope. It, too, may be selectively imprinted upon throughthe use of spot carbon on the back side of ply 28. Like the ply 28, ply38 includes die cuts on margins 40, 42 and 44 so that such margins arefree from attachment to the interior of the mailer. The ply 38 is alsoprovided with a stub 46 separated from the remainder of the ply 38 by aline of weakening 48. The stub 46 serves as an attaching portion for theply 38 in the same fashion as the stub 34 serves as an attaching portionfor the ply 26.

The ply 38, adjacent its upper edge, includes a line of weakening 50which serves to define a flap 52 for the return envelope. On the backside of the flap 52 is a moistenablev adhesive 54 whereby the returnenvelope may be sealed.

If desired, angled cuts 56 may be provided at the corners of the flap52. i

A ply 58 defines the back of the return envelope and a covering portionfor the adhesive 54. Specifically, the ply 58 includes a return envelopeback-defining portion 60 which is separated from the remainder of theply 58 by transverse slit 62 that aligns approximately with the v lineof weakening 50 on the ply 38 and a longitudinal partial slit 64. Thepartial slit 64 is not continuous as at 66 and 68 so as to define small,easily rupturable or breakable tongues interconnecting the back-definingportion with the remainder of the ply 58.

The upper and lower margins 70 and 72 of the ply 58 ware die cut so asto free the ply 58 from attachment to the mailer along those margins.The margin 74 is also die cut but, as seen in FIG. 3, extends somewhatto the right of the margins'30 and 42 on the plies 26 and 38.

As a result, it will be seen that in addition to the return envelopeback-defining portion 60, ply 58 includes a generally lrshaped chip 76.The chip 76 in turn defines a covering portion 80, defined by theupright of the L and an attaching portion 81 defined by the base of theL. As can be seen, the covering portion is aligned with the adhesive 54to cover the same.

Finally, the ply 58 includes a stub 78 separated from the remainder ofthe ply by a line of weakening 82, which stub 78 functions as anattaching portion for the ply 58.

A ply 83 defines the back of the mailer. It includes a stub 84 at oneside thereof separated from the remainder of the ply by a line ofweakening 85.

Each envelope 12 comprises the foregoing part and is secured inassembled relation as by glue lines. For example, glue lines 86(indicated as Xs in FIG. 3) secure the stubs 24, 34, 46, 78 and 84together to define a single unitary tear-off strip. A transverse glueline 88 on the upper and lower margins of the ply 83 serves to assemblethe outer envelope. Specifically, the glue lines 88 secure ply 83 to theply 22. In addition, along one longitudinal margin, a glue line 90 isprovided, which glue line also serves to secure the plies 83 and 22 toeach other to define a completely sealed mailer.

A glue line 98 extends between the ply 82 and the base of the L-shapedchip 76 to secure the latter to the outer envelope.

Finally, to complete the return envelope defined by plies 38 and 58, aglue line 100 extends about three marginal edges up the ply 38 withinthe line of weakening 48.

From the foregoing, it will be appreciated that removal of the tearstrip defined by the stubs 24, 34, 46, 78 and 84 will substantially freethe contacts from the outer envelope of the mailer, In this respect, theply 26, if present, will be completely free, while the plies 38 and 58will be held only by the tongues 66 and 68. The tongues 66 and 68 are soweak that a gentle pull on the return envelope defined by the plies 38and 58 will result in their severance and the free removal of the returnenvelope. Due to the presence of the glue line 98, the L-shaped chip 76will remain within the outer envelope and may be discarded therewith.However, prior to such removal of the return envelope, it will be appreciated that the covering portion 80 has served to cover the adhesive54 during storage and mailing. Thus, a continuous form envelope assemblymade according to the invention eliminates any need for the recipient toremove a chip or an adhesive protective tape prior to sealing the returnenvelope. It therefore renders a mailer easier to use and eliminates anypossibility that the flap 52 on the return envelope would be removedrather than the removable chip.

We claim:

1. In a continuous forms envelope assembly wherein a plurality ofelongated, superimposed plies including transverse lines of weakeningdefining individual envelopes which may be separated from the assemblytherealong and wherein upper and lowermost ones of the plies definefronts and backs of envelopes with intermediate plies defining insertmaterial within each envelope including at least a return envelope, thereturn envelope being defined by portions of adjacent intermediateplies, respectively defining the front and back of the return envelope,one of said adjacent plies further including an envelope flap that maybe folded about and secured to the other of said adjacent plies forclosing the return envelope and wherein the intermediate plies areconstructed so that the insert material is free from the outer envelopealong at least two, opposed, marginal edges of the outer envelope, theimprovement wherein said other adjacent ply has an attaching portionsecured to the outer envelope, said attaching portion being attached toa covering portion which is in substantial abutment with said flap; saidattaching portion and said covering portion being loosely secured to theremainder of said other adjacent ply so that upon the opening of theouter envelope, the return envelope can be easily extracted with saidattaching portion and said covering portion remaining interiorly of theouter envelope.

2. A continuous forms envelope assembly according to claim 1 whereinsaid one adjacent ply having said flap thereon further includes amoistenable adhesive on the side of said flap facing said other adjacentply and abutting said covering portion.

3. A continuous forms envelope assembly according to claim 2 whereinsaid adjacent plies defining said return envelope are configured todefine a top opening envelope and wherein said attaching portion andsaid covering portion are defined by an L-shaped chip.

4. A continuous forms envelope assembly comprising: a plurality of atleast four superimposed, elongated plies of paper, a first of said pliesdefining the fronts of outer envelopes; a second of said plies definingone of the fronts and the backs of return envelopes within the outerenvelopes, a third of the plies defining the other of the fronts and thebacks of the return envelopes within the outer envelopes, and the fourthof the plies defining the backs of the outer envelopes; said pliesincluding transverse lines of weakening defining individual envelopeswhich may be separated from the assembly therealong; said first andfourth plies being secured to each other about at least three marginaledges to define a sealed outer envelope; one of said second and thirdplies having at least two, opposed, marginal edges free from connectionto said outer envelope and a flap extending along one marginal edge todefine a sealing flap for the return envelope; the other of said secondand third plies having at least one marginal edge secured to said outerenvelope and a covering portion extending from said marginal edge inalignment and in substantial abutment with said flap, means separatingsaid marginal edge and said covering portion from the remainder of saidother of said second and third plies; and means securing said remainderto said one of said second and third plies to define said returnenvelopes.

5. A continuous forms envelope assembly according to claim 1 whereinsaid attaching and covering portions are loosely secured to saidremainder by small, easily rupturable tongues in a partial slitseparating said attaching and covering portions from said remainder.

1. In a continuous forms envelope assembly wherein a plurality ofelongated, superimposed plies including transverse lines of weakeningdefining individual envelopes which may be separated from the assemblytherealong and wherein upper and lowermost ones of the plies definefronts and backs of envelopes with intermediate plies defining insertmaterial within each envelope including at least a return envelope, thereturn envelope being defined by portions of adjacent intermediateplies, respectively defining the front and back of the return envelope,one of said adjacent plies further including an envelope flap that maybe folded about and secured to the other of said adjacent plies forclosing the return envelope and wherein the intermediate plies areconstructed so that the insert material is free from the outer envelopealong at least two, opposed, marginal edges of the outer envelope, theimprovement wherein said other adjacent ply has an attaching portionsecured to the outer envelope, said attaching portion being attached toa covering portion which is in substantial abutment with said flap; saidattaching portion and said covering portion being loosely secured to theremainder of said other adjacent ply so that upon the opening of theouter envelope, the return envelope can be easily extracted with saidattaching portion and said covering portion remaining interiorly of theouter envelope.
 2. A continuous forms envelope assembly according toclaim 1 wherein said one adjacent ply having said flap thereon furtherincludes a moistenable adhesive on the side of said flap facing saidother adjacent ply and abutting said covering portion.
 3. A continuousforms envelope assembly according to claim 2 wherein said adjacent pliesdefining said return envelope are configured to define a top openingenvelope and wherein said attaching portion and said covering portionare defined by an L-shaped chip.
 4. A continuous forms envelope assemblycomprising: a plurality of at least four superimposed, elongated pliesof paper, a first of said plies defining the fronts of outer envelopes;a second of said plies defining one of the fronts and the backs ofreturn envelopes within the outer envelopes, a third of the pliesdefining the other of the fronts and the backs of the return envelopeswithin the outer envelopes, and the fourth of the plies defining thebacks of the outer envelopes; said plies including transverse lines ofweakening defining individual envelopes which may be separated from theassembly therealong; said first and fourth plies being secured to eachother about at least three marginal edges to define a sealed outerenvelope; one of said second and third plies having at least two,opposed, marginal edges free from connection to said outer envelope anda flap extending along one marginal edge to define a sealing flap forthe return envelope; the other of said second and third plies having atleast one marginal edge secured to said outer envelope and a coveringportion extending from said marginal edge in alignment and insubstantial abutment with said flap, means separating said marginal edgeand said covering portion from the remainder of said other of saidsecond and third plies; and means securing said remainder to said one ofsaid second and third plies to define said return envelopes.
 5. Acontinuous forms envelope assembly according to claim 1 wherein saidattaching and covering portions are loosely secured to said remainder bysmall, easily rupturable tongues in a partial slit separating saidattaching and covering portions from said remainder.